Lead the Bit Rotary Steerable Tool

ABSTRACT

In one aspect of the present invention, a drilling assembly comprises a drill bit comprising a bit body intermediate a working face and a shank. An indenting member adapted to guide the drill bit protrudes from the working face. A flexible portion is disposed above the bit body.

CROSS REFERENCE TO RELATED APPLICATIONS

This Patent Application is a continuation-in-part of U.S. patent application Ser. No. 11/837,321, which is a continuation-in-part of U.S. patent application Ser. No. 11/750,700, which is a continuation-in-part of U.S. patent application Ser. No. 11/737,034, which is a continuation in-part of U.S. patent application Ser. No. 11/686,638 which is a continuation-in-part of U.S. patent application Ser. No. 11/680,997 which is a continuation-in-part of U.S. patent application Ser. No. 11/673,872 which is a continuation-in-part of U.S. patent application Ser. No. 11/611,310, which is a continuation in-part of U.S. patent application Ser. No. 11/278,935 which is a continuation-in-part of U.S. patent application Ser. No. 11/277,294 which is a continuation-in-part of U.S. patent application Ser. No. 11/277,380 which is a continuation-in-part of U.S. patent application Ser. No. 11/306,976 which is a continuation-in-part of U.S. patent application Ser. No. 11/306,307 which is a continuation-in-part of U.S. patent application Ser. No. 11/306,022 which is a continuation-in-part of U.S. patent application Ser. No. 11/164,391. All of these applications are herein incorporated by reference in their entirety and their priorities claimed.

BACKGROUND OF THE INVENTION

This invention relates to the field of tools used in directional drilling. More specifically, the invention includes a flexible portion disposed in a drill string to facilitate drilling inclined wellbores. The prior art includes several methods for steering a tool string. An embodiment of a bent sub system is generally depicted in FIG. 1 a. In this embodiment, the drill string comprises a bent sub 2050 above the drill bit 2051. A hydraulic motor housed within the bore of the drill string components rotates the drill bit below the bent sub 2050. As drilling mud is passed through the drill string the motor turns in response to the flow rotating a portion 2052 of the drill string below the bent sub. The portion 2053 above the bent sub does not rotate from the motor, but slides through the hole as the drill bit advances into the earth. The bent sub directs the drill strings trajectory in relation to the angle of the bent sub.

An embodiment of a push the bit system is generally depicted in FIG. 1 b. In this embodiment, an extendable pad 2150 is located above the drill bit 2051. Typically there is more that one pad oriented around the outer surface of the drill string near the bit that are timed together so as to extend at the same azimuth with relation to the well bore while the drill string is rotating. Each time a pad extends, it pushes the drill bit off course and may be used to control the drill string's trajectory.

Yet another embodiment for steering bit includes point the bit systems where the drill bit is actively positioned from further up the drill string.

Variations of these systems are disclosed in the following prior art documents. U.S. Pat. No. 5,529,133 to Eddison, which is hereby incorporated by reference for all that it contains, discloses a steerable rotary drilling tool that includes a drill bit mounted on the lower end of a housing by a drive shaft having an articulative coupling that allows the bit's rotation axis to be inclined relative to the rotation axis of the housing, an eccentric weight in the housing that maintains the bit axis pointed in only one direction in space as the bit is turned by the housing, and a clutch system that allows such direction to be changed downhole. A measuring-while-drilling tool is included to allow the progress of the drilling to be monitored at the surface, and to allow changing the bit axis or toolface by a selected amount.

U.S. Pat. No. 5,078,650 to Foote which is herein incorporated by reference for all that it contains discloses a universal joint arrangement that includes a first adapter having two projecting support formations; a drive plate having a first pair of matching depressions or pockets is seated with these depressions on the projecting support formations of the first adapter and the drive plate has a second pair of pockets for the projecting support formations of a respective second adapter.

U.S. Pat. No. 7,188,685 to Downton which is herein incorporated by reference for all that it contains discloses a bottom hole assembly that is rotatably adapted for drilling directional boreholes into an earthen formation. It has an upper stabilizer mounted to a collar, and a rotary steerable system. The rotary steerable system has an upper section connected to the collar, a steering section, and a drill bit arranged for drilling the borehole attached to the steering section. The steering section is joined at a swivel with the upper section. The steering section is actively tilted about the swivel. A lower stabilizer is mounted upon the steering section such that the swivel is intermediate the drill bit and the lower stabilizer.

BRIEF SUMMARY OF THE INVENTION

In one aspect of the present invention, a drilling assembly includes a drill bit body disposed intermediate a working face and a shank. The shank may be attached to a drill string. The working face comprises an indenting member protruding from the working face, the indenting member being adapted to guide the drill bit. A flexible portion is disposed above the bit body to allow angular deflection of the bit with respect to the drill string.

The flexible portion may comprise upper and lower segments, and may be disposed intermediate the bit body and the shank or may be disposed intermediate the shank and an adjacent drill string component. The lower segment of the flexible portion may comprise an extension with a generally spherical distal end, and a corresponding spherical recess may be disposed in the upper segment. Bearing balls adapted to transfer torque may be retained in recesses and/or grooves in the spherical portions of the upper and lower joint segments. In another embodiment, the flexible portion may comprise one or more universal joints. The portion may comprise a compliant segment. The flexible portion may comprise a joint with laterally sliding surfaces.

The indenting member may be rotatable with respect to the bit body. A shaft may be disposed internal to the bit body and intermediate the indenting member and a rotating element such as a fluid-driven turbine, mud motor, or an electric motor. The shaft may be flexible, and may comprise a compliant portion, one or more universal joints, or a constant velocity joint.

The indenting member may comprise asymmetrical geometry on the distal end, and may comprise a polycrystalline diamond cutting element. The polycrystalline diamond cutting element may comprise pointed geometry.

The assembly may comprise a mechanism adapted to selectively prevent movement of the portion for drilling straight wellbores. The mechanism may be adapted to selectively limit angular deflection of the flexible portion, and may self-align the portion to a position of zero angular deflection.

The assembly may comprise a wiper seal disposed intermediate the moveable sections of the portion. The assembly may also comprise a bellows-type seal disposed exterior to the portion.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 a is a cross-sectional view of an embodiment of the prior art.

FIG. 1 b is a cross-sectional view of another embodiment of the prior art.

FIG. 1 c is a cross-sectional view of an embodiment of a drill string suspended in a borehole.

FIG. 2 is a cross-sectional view of an embodiment of a drilling assembly.

FIG. 3 is a cross-sectional view of an embodiment of a drilling assembly.

FIG. 4 is a cross-sectional view of another embodiment of a drilling assembly.

FIG. 5 is a cross-sectional view of another embodiment of a drilling assembly.

FIG. 6 is a perspective view of an embodiment of a universal joint.

FIG. 7 a is a cross-sectional view of another embodiment of a drilling assembly.

FIG. 7 b is a cross-sectional view of another embodiment of a drilling assembly.

FIG. 8 a is a perspective view of an embodiment of an indenting member.

FIG. 8 b is a perspective view of another embodiment of an indenting member.

FIG. 8 c is a perspective view of another embodiment of an indenting member.

FIG. 8 d is a perspective view of another embodiment of an indenting member.

FIG. 9 is a cross-sectional view of another embodiment of a drilling assembly.

FIG. 10 a is a cross-sectional view of another embodiment of a drilling assembly.

FIG. 10 b is a cross-sectional view of another embodiment of a drilling assembly.

FIG. 10 c is a detailed view of another embodiment of a drilling assembly.

FIG. 11 a is a cross-sectional view of another embodiment of a drilling assembly.

FIG. 11 b is a cross-sectional view of another embodiment of a drilling assembly.

FIG. 12 is a cross-sectional view of another embodiment of a drilling assembly.

FIG. 13 is a cross-sectional view of another embodiment of a drilling assembly.

FIG. 14 is a cross-sectional view of another embodiment of a drilling assembly.

DETAILED DESCRIPTION OF THE INVENTION AND THE PREFERRED EMBODIMENT

FIG. 1 c discloses a drill string 100 suspended in a borehole 103 by a derrick 101. A drilling assembly 102 is connected to the end of the drill string 100 and comprises a drill bit 104. As the drill bit 104 rotates the drill string advances in the formation 105. The drill string 100 may comprise one or more flexible portions 106 to allow directional drilling.

FIG. 2 discloses an embodiment of a drilling assembly 102. The drilling assembly 102 may comprise a drill bit 104 with a working face 106, an indenting member 107 protruding from the working face 106, and a shank 108. A compliant segment 113 may be disposed intermediate the shank 108 and a portion of the drill string 109. The compliant segment 113 may comprise a portion of reduced cross-section 110 to provide elastic angular deflection with respect to an axial centerline of the portion of the drill string 109. Cross-sectional area may be reduced by a taper, a series of circumferential or axial grooves, or one or more helical grooves or via a more elastic material. The compliant segment 113 may be constructed from any material with sufficient strength and suitable elastic modulus, such as high-strength steel or other metal or metal alloy. The drilling assembly 102 may comprise a shaft 111 intermediate the indenting member 107 and a rotating element 114 such as a fluid powered turbine, mud motor or an electric motor. The shaft 111 may comprise a compliant portion 112 to allow deflection in the shaft 111 corresponding to the deflection in the compliant segment 113.

The indenting member may be asymmetric such that as it indents into the formation it leads the bit away from straight trajectory. The rotating element above may be used to position the apex of the indenting member at the desired azimuth for the drill string to follow. In such a manner, the driller may control the drill string trajectory. In some embodiments, it may be desirable for the drill string to drill in a straight trajectory, in such cases, the indenting member may be randomly or otherwise rotated such that it leads the bit in a straight direction.

The ability of the indenting member to steer depends on the ability of the asymmetric indenting member to push off of the formation. In soft formations, the formation may push back on the indenting member less. Thus, the flexible portion may lower the amount of formation side push back on the indenting member required to alter the path of the drill bit.

FIG. 3 discloses a drilling assembly 102 according to the present invention. The drilling assembly 102 may comprise a drill bit 104 with a working face 106, an indenting member 107 protruding from the working face 106, and a shank 108. The shank 108 is connected to a flexible portion 209. The flexible portion 209 comprises an upper segment 210 and a lower segment 211, the lower segment comprising an extension 212 with a generally spherical portion 213. The upper segment 210 comprises a generally spherical recess 214 corresponding to the generally spherical portion 213 of the lower segment 211. The generally spherical portion 213 is moveably retained in the generally spherical recess 214. The generally spherical recess 214 comprises a plurality of reliefs 215 which hold a plurality of bearing balls 216. The generally spherical portion 213 of the lower segment 211 comprises a plurality of grooves 217, the bearing balls 216 extending into the grooves 217. The bearing balls 216 are free to slide or rotate in the grooves 217 and reliefs 215, thus allowing angular deflection of the lower segment 211 with respect to the upper segment 210, while providing torque transmission through the flexible portion 209 as the drilling assembly 102 rotates. The bearing balls 216 may be retained in a bearing cage. The bearing balls may be constructed from high strength steel and may be case hardened, heat treated, or otherwise processed to provide sufficient strength. Other suitable materials such as other metals, metal alloys, or ceramic may be used. The reliefs and grooves that retain the bearing balls may also be heat treated, case hardened, or otherwise processed to mitigate abrasive wear.

The upper segment 210 may comprise a mechanism that selectively prevents movement of the lower segment with respect to the upper segment. In this embodiment, a plurality of stops 219 are disposed inside the upper segment 210 and may be brought into contact with the lower segment 211, thus preventing angular deflection of the portion 209 and allowing the drilling assembly 102 to drill a straight borehole. The plurality of stops may be actuated by a mechanical, hydraulic, or electronic system or combinations thereof.

The upper segment 210 of the flexible portion 209 comprises a face 220 with convex generally spherical geometry, and the lower segment 211 comprises a face 221 with concave generally spherical geometry. The faces on the upper and lower segments have a common substantially constant radius of curvature, with the center of curvature in the same location as the center of curvature of the generally spherical portion 213 and the generally spherical recess 214. The faces 220 and 221 are in slideable contact, thus allowing angular deflection of the lower segment 211 with respect to the upper segment 210. The faces 220 and 221 may be heat treated, case hardened, or coated with a wear resistant material such as polycrystalline diamond, a low-friction material such as PTFE, or other wear resistant and/or low friction coating.

The drilling assembly 102 may also comprise a shaft 111 intermediate the indenting member 107 and a rotating element 114 such as a fluid-powered turbine or electric motor. The shaft 111 may comprise a compliant portion 112 to allow deflection corresponding to the deflection of the flexible portion 209.

Referring now to FIG. 4, the plurality of stops 219 are removed from contact with the lower segment 211, thus allowing greater angular deflection 401 of the lower segment 211 with respect to the upper segment 210. The indenting member 107 may comprise asymmetrical geometry on the distal end 401. As the drilling assembly 102 rotates, the rotating element 114 rotates the shaft 111 with an angular velocity having the same magnitude but opposite direction of the angular velocity of the drilling assembly 102. Thus, the indenting member 107 has zero angular velocity with respect to the formation 105, and the asymmetrical geometry on the distal end 401 guides the bit 104 through the formation 105 in an azimuth direction determined by the orientation of the indenting member 107.

In some embodiments the flexible portion is moved passively in consequence of the deflections caused by the indenting member.

The plurality of stops 219 may selectively constrain the angular deflection of the flexible portion 209 to any angle in an interval including zero angle, or non-deviated drilling, to the maximum angle attainable by the flexible portion 209.

FIG. 5 discloses another embodiment of a drilling assembly 102 according to the present invention. In this embodiment, the drilling assembly 102 comprises a drill bit 104 comprising a working face 106 and a shank 108. A flexible portion 209 is disposed intermediate the working face 106 and the shank 108. The shank 108 is connected to a drill string 501.

FIG. 6 discloses an embodiment of a universal joint 601. The universal joint 601 comprises an inner portion 602 and an outer portion 603. The inner portion 602 is attached to the outer portion 603 by a spider 604 comprising bearing carriers 605.

Referring now to FIG. 7 a, a drilling assembly 102 comprises a drill bit 104 with a working face 106 and a shank 108. The drill bit 104 comprises a flexible portion 209 intermediate the working face 106 and the shank 108. The flexible portion comprises an upper portion 701 and a lower portion 702, the lower portion comprising an extension 703. A universal joint spider 604 comprises generally cylindrical bearing carriers 605 and is disposed such that the axial centerline 606 of the bearing carriers 605 intersects the center of curvature of a generally spherical interface 704. The bearing carriers 605 are held in bushings 607 or bearings in the upper portion 701 of the flexible portion 209.

FIG. 7 b discloses the same embodiment as FIG. 7 a, with the drilling assembly 102 rotated 90 degrees. The universal joint spider 604 comprises generally cylindrical bearing carriers 608, the axial centerline 609 of which intersects the center of curvature of the generally spherical interface 704. Bearing carriers 608 extend into bushings 610 or bearings disposed in the extension 703 of the lower portion 702. The bushings 607 and 610 may be made from any suitable material including bronze, steel, Babbitt metal, or a polymer.

FIG. 8 a discloses an embodiment of an indenting member 107. In this embodiment, a polycrystalline diamond compact 801 is brazed or otherwise affixed to the distal end of a shank 802. The polycrystalline diamond compact 801 may be disposed coaxial to the shank 802, and the polycrystalline diamond compact 801 may comprise pointed geometry. The shank 802 may be constructed from a steel alloy, and may be case hardened, heat treated, or otherwise processed to improve abrasion resistance. The shank may comprise hard-facing.

FIG. 8 b discloses another embodiment of an indenting member 107. In this embodiment, a polycrystalline diamond compact 801 is brazed or otherwise affixed to the distal end of a shank 802. The axial centerline of the polycrystalline diamond compact 801 and the axial centerline of the shank 802 may be offset.

FIG. 8 c discloses another embodiment of an indenting member 107. A shank 802 comprises a distal end 803 which may be cast, machined, forged, or otherwise formed into a generally polygonal shape. The generally polygonal shape may be asymmetric with respect to the axial centerline of the shank 802.

FIG. 8 d discloses another embodiment of an indenting member 107. In this embodiment, the indenting member 107 comprises a shank 802 and a distal end 803. The distal end 803 may comprise generally conical geometry, and may be asymmetric with respect to the axial centerline of the shank 802. The distal end 803 may comprise hard-facing or other material or treatment intended to reduce abrasive wear.

FIG. 9 discloses another embodiment of a drilling assembly 102 according to the present invention. Drilling assembly 102 comprises a flexible portion 209 disposed intermediate a drill bit 104 and a portion of drill string 109. The flexible portion 209 comprises an interface 901 intermediate an upper segment 210 and a lower segment 211. The interface 901 may be protected from abrasion and wear by a bellows-type cover 902. The cover 902 may be made from electron-beam welded sheet metal or another material.

The interface 901 may comprise a seal 903 disposed intermediate the upper segment 210 and the lower segment 211. The seal 903 may comprise an o-ring or wiper seal, and may be adapted to retain lubrication on the interface 901. The interface 901 may be sealed from contact with drilling fluid, or may be open to the drilling fluid.

A shaft 111 may be disposed intermediate the indenting member 107 and a rotating element 114. In this embodiment, the shaft 111 comprises two universal joints 904 adapted to allow the shaft 111 to deflect according to the deflection of the flexible portion 209.

FIG. 10 a discloses another embodiment of a drilling assembly 102. In this embodiment, the drilling assembly comprises a flexible portion 209 and includes a sliding collar 1001 comprising ports 1002. Fluid passages 1003 are in communication with a plurality of pistons 1004. Pistons 1004 are attached to mechanical stops 219.

Referring now to FIG. 10 b, a drilling assembly 102 comprises a sliding collar 1001. Ports 1002 in the sliding collar 1001 are in communication with a plurality of fluid passages 1003. Drilling fluid is diverted into and creates fluid pressure in passages 1003.

Referring now to FIG. 10 c, which is a detailed view of FIG. 10 b, a drilling assembly 102 comprises a flexible portion 209 and a plurality of fluid passages 1003. Fluid pressure in the passages 1003 forces a plurality of pistons 1004 and mechanical stops 219 inward to contact a lower segment 211 of the flexible portion 209. Flexible portion 209 is thus immobilized to allow drilling straight wellbores.

FIG. 11 a discloses another embodiment of a drilling assembly 102. In this embodiment, a lower segment 211 of a flexible portion 209 comprises a threaded sleeve 1101 engaged with a threaded collar 1102. The threaded sleeve 1101 is free to rotate on an extension 212 of a lower segment 211 of the flexible portion 209. An electric motor 1103 rotates the threaded sleeve 1101, and alignment pins 1104 prevent rotation of the threaded collar. As the electric motor 1103 rotates the threaded sleeve 1101, the non-rotating threaded collar 1102 moves upward. Maximum angular deflection of the flexible portion 209 can be controlled by adjusting the position of the threaded collar, and as the collar moves upward it aligns the portion to a position of zero angular deflection.

Referring now to FIG. 11 b, a drilling assembly comprises a threaded collar 1102 engaged with a rotatable threaded sleeve 1101. The threaded collar 1102 is in maximum upward position, effectively immobilizing a flexible portion 209 to allow straight drilling.

FIG. 12 discloses another embodiment of a drilling assembly 102. In this embodiment, a collar 1201 comprises a distal end 1202 with generally conical geometry 1203. A flexible portion 209 comprises a lower segment 211 with an extension 212 which also comprises generally conical geometry 1204. The collar may be movable in a direction coaxial with an axial centerline 1205 of the drilling assembly 102. The position of the collar 1201 determines the maximum angular deflection of the lower portion 211 of the flexible portion 209. The position of the collar 1201 may be controlled by a mechanical, electronic, hydraulic, or other system, or combinations thereof. As the collar 1201 moves toward the lower portion 211 of the flexible portion 209, the generally conical geometries 1203 and 1204 are brought into mechanical contact and the lower portion of the joint 211 self-aligns with the collar 1201 and the flexible portion 209 reaches a position of zero angular deflection.

FIG. 13 discloses another embodiment of a drilling assembly 102. A drill bit 104 comprises a plurality of grooves 1301 intermediate a working face 106 and a shank 108. The grooves 1301 may be circumferential, helical, or otherwise oriented and may be machined, forged, cast, or otherwise formed in the drill bit 104. The grooves 1301 allow for elastic angular deflections in the drill bit 104.

FIG. 14 discloses another embodiment of a drilling assembly 102. A flexible portion 209 is disposed intermediate a drill bit 104 and a portion of drill string 109. The flexible portion 209 comprises a compliant segment 1401 and an outer sleeve 1402. A collar 1403 is moveable in a direction coaxial to an axial centerline 1205 of the drilling assembly 102. Mechanical stops 1404 are disposed internal to the outer sleeve 1402. The collar 1403 may selectively be brought into mechanical contact with the stops 1401, thus limiting or disallowing angular deflection of the compliant segment 1401 and the drill bit 104.

Whereas the present invention has been described in particular relation to the drawings attached hereto, it should be understood that other and further modifications apart from those shown or suggested herein, may be made within the scope and spirit of the present invention. 

1. A drilling assembly, comprising: a drill bit comprising a bit body intermediate a working face and a shank; an indenting member protruding from the working face, the indenting member being adapted to guide the drill bit; and a flexible portion disposed above the bit body.
 2. The assembly of claim 1, wherein the flexible portion is intermediate the body and the shank. 3 The assembly of claim 1, wherein the flexible portion is intermediate the shank and an adjacent drill string component.
 4. The assembly of claim 1, wherein the flexible portion comprises upper and lower segments, the lower segment comprising an extension with generally spherical geometry on the distal end, the upper segment comprising a corresponding generally spherical recess.
 5. The assembly of claim 4, wherein the flexible portion comprises bearing balls adapted to transfer torque disposed in recesses and/or grooves in the generally spherical portions of the upper and lower segments.
 6. The assembly of claim 1, wherein the flexible portion comprises at least one universal joint.
 7. The assembly of claim 1, wherein the flexible portion comprises a compliant segment.
 8. The assembly of claim 1, wherein the indenting member is rotatable with respect to the bit body.
 9. The assembly of claim 1, wherein a shaft is disposed internal to the bit body, intermediate the indenting member and a rotating element.
 10. The assembly of claim 9 wherein the shaft is flexible.
 11. The assembly of claim 9 wherein the rotating element is a fluid-driven turbine.
 12. The assembly of claim 9, wherein the shaft comprises at least one universal joint.
 13. The assembly of claim 9, wherein the shaft comprises a compliant portion.
 14. The assembly of claim 9, wherein the shaft comprises a constant-velocity joint.
 15. The assembly of claim 1, wherein the indenting member comprises asymmetrical geometry on the distal end.
 16. The assembly of claim 1, wherein the indenting member comprises a polycrystalline diamond cutting element.
 17. The assembly of claim 16 wherein the cutting element comprises pointed geometry.
 18. The assembly of claim 1, wherein the assembly comprises a locking mechanism adapted to selectively prevent movement of the flexible portion
 19. The assembly of claim 1, wherein the assembly comprises a wiper seal disposed intermediate the flexible portion and the bit body.
 20. The assembly of claim 1, wherein the assembly comprises a bellows-type seal disposed exterior to the flexible portion 